Switch connector for spotlights



sept. 12, 195o H. R. GROSS 2,521,911

SWITCH CONNECTOR FOR SPOTLIGHTS Filed Dec. r5, 1947 Patented Sept. 12, 1950 UNITED STATES PATENT OFFICEy SWITCH CONNECTOR FOR SPOTLIGHTS Henry R. Gross, Chicago, Ill.

Application December 3, 1947, Serial No. 789,363

1 IClaim.

This invention relates to a switch connector for a rotary conductor, and more particularly to a switch connector for the rotary conductor of a dirigible spot light.

In dirigible spot lights, it is most convenient to provide a rotatable conductor having rotary contact terminals at its opposite ends to connect a control unit mounted in a position inside an automobile to a lamp unit mounted outside the automobile. Difficulty has been encountered in providing a satisfactory connection between a stationary switch mounted in the control unit and the rotary contact terminal of the rotatable conductor. This diiculty has been occasioned by the fact that tolerances allowed in the cutting and forming of the many parts which mechanically and electrically connect the control unit to the lamp unit are cumulative and cause a wide variation in the positioning of the rotary contact terminal of the rotatable conductor in the control housing. Some form of shiftable connector to wipe the rotary contact of the rotatable conductor must therefore be provided and its connector must be secured to a stationary part in the control housing effectively to secure it against rotation while bearing upon the rotary contact irrespective of the position which it may occupy in the control housing due to the accumulated tolerances. This connector must be connected to a control switch, mounted in the control housing, and this control switch must be ixed in position to cooperate with a switch operator extending from the housing to a predeterminedly located opening closely fitting the switch operator. unit be as small as possible in order that it may infringe as little as possible upon the drivers vision and with his manipulations of the various controls necessary to handle the modern automobile. It is also essential to the economical manufacture of the spot light that the maximum number of parts be formed by die castings, stampings and other mass production methods which require that provision be made for mounting each of the various parts in xed position.

It is accordingly an object of this invention to provide a control unit meeting the above specications, and more particularly to provide a combined switch and connector assembly for the control unit, which assembly shall occupy the minimum of space and permit a movement of the connector lpart a suicient distance to take up all of the cumulative tolerances and yet bear against the rotary contact terminal with suf- It is essential that the control'l CII cient force to insure a good electrical connection under all conditions.

A further object of the invention is to provide a connector switch for such use which is comprised of a minimum number of parts which can be readily assembled by assembly line methods of mass production.

Other and further objects and advantages of the invention will be apparent from the following description when taken in connection with the accompanying drawings wherein:

Fig. 1 is a View in perspective of a control unit embodying the present invention;

Fig. 2 is a fragmentary view in vertical section taken along the lines 2-2 of Fig. 1;

Fig. 3 is an enlarged fragmentary view on a portion of Fig. 1 with additional parts being shown in section;

Fig. 4 is a view in vertical section taken along the line 4-4 of Fig. 3;

Fig. 5 is a view in vertical section taken along the line 5-5 of Fig. 3; and

Fig. 6 is an exploded View in 'perspective of the parts of the connector switch which is constructed in accordance with the present invention.

As shown in Fig. 1, a. control unit embodying the invention comprises a die casting 2 having an open rear control chamber 4 and a longitudinal bore 6 extending from the chamber 4 to one end of the housing casting 2. The bore E is provided with an inner enlarged portion to receive the hub of a beveled gear 8 keyed to a tube I0 in which there is mounted for rotation with the tube an insulating sleeve I2 and a conductor I4 carrying at its inner end a rotary contact terminal I6. The conductor I4, sleeve I2 and tube I0 are journaled in a sleeve I8 to rotate the dirigible spot light about a vertical axis, as is well known. The tube I8 is secured in any convenient manner to control unit housing 2 to rotate about its axis on revolution of the control unit thereby to cause revolution of the spot lamp about the horizontal axis, as is well known. The housing 2 is mounted on and supported by stationary tube 20, as is conventional. The control handle 22 is secured to a stud 24 formed with a beveled gear 26 and journaled in a bushing 28 threaded in an opening in the housing. The control chamber 4 of the housing is closed at its rear end by die cast cap 30 fitting at its forward end over a reduced annular flange 32 of the housing and the cap is detachably secured to the housing as by a screw 34 received by a suitable opening in the rim of the cap 30 and threaded into a suitable opening, not shown, in the ilange 32. A connector switch 36 is mounted in this control chamber 4 and a space provided by the streamlined cap 3G. This connector switch comprises a molded mounting block 33 of Bakelite or other insulating plastic, switch blades 4G and 42, connector sleeve 44 and spring 4G. The mounting block 38 is formed with spaced projecting surfaces 48 on each side to receive and form a, seat for the switch blades 40 and 42 and with a but- 1 ton 50 on each side to be received in an opening 52 in the blade 40 and a like opening 54 in the blade 42 to locate the blades in proper position for cooperation with a switch operator. The mounting block is also provided with threaded openings 56 to receive an attaching screw.: 58' or Bil to fasten the switch blades thereto. .A threaded opening 62 in the top of the block '38 receives a mounting screw 64 by means otwhich the switch is mounteddn the housing 2, as illustrated-in 1Fig. 2. The switch blade 401 isormed with a lateral lug 66 andthe switch blade 42 with a dependent lug 68the lug 68 extending beneath the..block,38 and terminating` as illustrated in Fig. 4 just short of the lug 68 of the blade 42. The mounting block 38 is also formed with an opening 'IU having opposite ilat sides and eX- tendingirom the rear of the mounting block longitudinally thereof to an enlarged circular opening .'12` extending.longitudinally to the 4forward face of the block. The connector sleeve 44 has an Venlarged head 14 which forms a contact terminal or brush to engage the rotary contact terminal i6 and the inner 4portion of the sleeve is flattened at opposite sides las at l to crimp the sleeve-toa bared wire 'i8 and to hold the sleeve against rotationwhen itis inserted in the opening 'l0 of the mounting block. It should vbe noted that the yopening l2 inthe block -38 is of greater diameter than the head 'i4 of-tliefconnector.sleeve and alsoof greater diameter than. the*V rotary contact terminal l. The `coil vspring 46 is rec eived inthe opening 12 and .bears atone `end against the internal shoulder formed by `the openingv and at the other .end againstthe yhead 14 of the connector sleeve. 'The spring urges the connector sleeve outwardly into resilient engagement with .the rotary contact terminal 4.Hi and allows the sleeve to be extended from the bloclc .38 or it necessary to .be retracted into the block to` accommodate the cumulative tolerances which cause the .rotary Contact terminal i6 to assume different positions or -spacings from the switch block 38.

The bared wire TSpasses through the openingl 'mainthe block-38 and islooped over along vthe switch. .blade '40. towhich .it yis soldered at its free end as at 8G. The wire 'I8 is sufficiently flexible and made suciently long to permit the-required extension andretraction of the connector. sleeve.

VThe switch operator comprises a die cast cup 82 having a iinger piece 84 secured as by a pin 86 to a bosso ofthe cap 3|]v so thatthe operator extends out of. the control housing through a suitable `opening in the cap.. 30. An insulating cup .88? is press tted intothe cup 82 and a metal cup shellSlO- is press fitted into the insulating cup 88. The cup 9e receivesswitchpin 92 and is peened. overtoretainthe pin. The pin is providedfwith a peripheral flange 95 against which a spring 98. bears at one end, the` spring bearing at its other end against thebottom of themetal` cup 93. The spring 93 resilientlyurges the pin in contacting engagementwith the lug 6E of the- 4 switch blade 40. When the switch operator is swung in a, counter-clockwise direction, as seen in Fig. 4, the switch pin 92 bridges the gap between the switch lug 66 and the switch lug 68'.

A hot wire lead-in I extends into the control chamber 4 to a suitable opening m2 in the side wall of the housing 2. The conductor is supported in a notch |04 of the outer end of the switch blade 40 and its bared end is received n an aperture LEG `in the end of theswitch blade 42 and is soldered to that end.

In assembly of the parts with the control housing 2 the gear B is rst mounted in the chamber. 4, `the gear 2G attached tol the handle stud 24 and the sleeve 28 is introduced into the chamber 4 and the sleeve 28 tightened to hold the parts in such relation. The switch block 38, with'its associated parts mounted thereon, is -mounted in chamber il by screw 64 and the cap 39 with the switch operator assembled there with isattached to the housing by;the.screw34. The assembly of themounting tubesz.- vI8 and lil, the sleevelZ, and the conductor i4 are Ainserted in the housing 2. The rotaryicontactterminal h5, atvthe end otthe conductor assumes a position in the chamberxl. which .Varies with the accumulated tolerances so .that its spacing relativeto the forward .edge of theblock 33.1nay vary considerably. Whatever. position itv assumes it engages the head I4 of .the connector sleeve 44 and depresses' it toward or into.. ,the block so that' drm electrical contact islestablisbed between the stationary head 14 of the connector 'sleeve and the rotary. contact terminal i6.

It will be apparent fromthe foregoing .description that applicant has provided a rotatable conductor having` rotary` Contact terminals at its opposite end to' connect` a control .unit mounted in a -position inside an automobile to a lamp unit mounted outside ythe automobile, and more particularly a combined switch and connector assembly for ythecontrolunit which shall occupy the minimum of-space and permit amovement of thev conncctorpart a sufcient distance-to: take upall o1" Ithe cumulative ltolerancesand Lyetbear` against the rotary contact terminal with sunc-ientiorce to insure af good electrical :connection under 'allconditions. Applicanthas also provided a-fconnector switch for such use. whichiscomprised 'ofa minimum number of parts which can-be lreadily assembled -by assembly line -methods` olf-mass production.

.-It :willi bei obvious that changes maybe made ini. the form,v construction and:arrangement-of the :parts without-departing from 'the spirit'iof Jthe;.invention or sacrificingV any-of its advantagesgfand theright isk hereby reserved-.to-make all such :changes vas 4fairly.alhwithin the: scope of the fol-lowingfclaim.

What Iclaim is.:

VA: connector switch fora rotary conductor comprising a stationary: mounting bloclcof` insulation, said .block having-.longitudinally extending grooves in: its opposite sides, switch bladesrmounted in said grooves and extending rearwardly ybeyond saidv block, one :ofv said blades having aportion extending transversely of'the block-andv terminatingjust short of. the switch bladeon the oppositeside of'the block, a-switch operator having a shiftably;` mounted `.member Iin engagement with said, portion of the; blade Vextend-ing; across, 'the- `biecht` andishiitable; thereE along to bridgelthe gap :between the bladesssaid block having a longitudinally extending openfing therein, said opening having at sides and opening to the rear side of the block and communicating with a larger opening opening into the forward face of the block, a connector pin having a portion with flat sides slidably and non-rotatably received in the first-mentioned opening in the block and an enlarged head smaller than said second-mentioned opening so that the pin may move into the block, and spring means mounted in said block and bearing at one end against the block and at the other end against the enlarged head of the connector pin to eX- tend the pin from the block and permit its retraction to the block in accordance with the spacing of the rotary conductor from the forward face of the block.

HENRY R. GROSS.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS 

